MSA 3600 User manual

Model 3600
Infrared Gas Monitor
instruction manual
WARNING
THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILL
HAVE THE RESPONSIBILITY FOR INSTALLING, USING OR SERVICING THIS PRODUCT. Like
anypieceofcomplex equipment,this product will performasdesignedonlyifinstalled,used
and serviced in accordance with the manufacturer’s instructions. OTHERWISE, IT COULD
FAIL TO PERFORM AS DESIGNED AND PERSONS WHO RELY ON THIS PRODUCT FOR
THEIR SAFETY COULD SUSTAIN SEVERE PERSONAL INJURY OR DEATH.
The warranties made by Mine Safety Appliances Company with respect to these products
are voided if the products are not installed, used and serviced in accordance with the
instructions in this manual. Please protect yourself and others by following them. We
encourage our customers to write or call regarding this equipment prior to use or for any
additional information relative to use or repairs.
INSTRUMENT DIVISION 1-800-MSA-INST or FAX [phone]
IN CANADA 1-800-267-0672 or FAX [phone]
MSA INTERNATIONAL [phone] or FAX [phone]
© Mine Safety Appliances Company 1993 - All Rights Reserved
Made in Switzerland for
MINE SAFETY APPLIANCES COMPANY
PITTSBURGH, PENNSYLVANIA 15230
(L) REV 2 800031

Warnings and Cautions
1. Each instrument described in this
manual should be installed, operated,
and maintained in strict accordance
with its labels, cautions, warnings,
instructions, and within the
limitations stated.
2. These monitors must not be installed in
areas or locations where explosive
concentrations of combustible gases or
vapors might occur in the atmosphere:
Class 1, Group A, B, C, and D areas
as defined by the NEC. Because the
monitors are not explosion-proof, they
must be located in non-hazardous
areas.
3. The Model 3600 Infrared Gas Monitor is
designed to detect carbon dioxide or
methane vapors in the air. It cannot
measure the concentration of these
gases or vapors in a steam type
atmosphere. Neither will it indicate the
presence of explosive or combustible
mists or sprays, lubrication oils, nor
explosive dusts such as grain or coal
dust.
4. As with all gas detection instruments of
this type, high levels of or long
exposure to certain compounds in the
tested atmosphere contaminate the
sensor. In atmospheres where the
monitor may be exposed to such
materials, calibration should be
performed frequently to ensure that
system operation is dependable and its
indications accurate.
5. The Model 3600 Infrared Gas Monitor
must not be painted. Also, painting
should not be done near the sample
line inlet. If painting is being done in
an area where the sample line inlet is
located, care must be exercised to
make sure that paint is not deposited
on the sample inlet fitting of the
monitor or sample line. Such paint
deposits would interfere with the
sampling process, whereby a sample of
the atmosphere being monitored is
drawn into the Model 3600 Infrared
Gas Monitor.
6. The only absolute method to assure the
proper overall operation of a gas
detection instrument is to check it
with a known concentration of the
gas for which it has been calibrated.
Consequently, a calibration check
should be included as part of the
routine inspection of the system.
7. The sensor is a sealed unit. No attempt
should be made to modify or adjust
the sensing element.
8. Perform periodic leak checks on the
sample line and all flow system
components and fittings of the Model
3600 Infrared Gas Monitor.
9. Use only genuine MSA replacement
parts when performing any
maintenance procedures provided in
this manual. Failure to do so may
seriously impair instrument
performance. Repair or alteration of
the Model 3600 Infrared Gas Monitor,
beyond the scope of these
maintenance instructions or by
anyone other than authorized MSA
service personnel, could cause the
product to fail to perform as
designed, and persons who rely on
this product for their safety could
sustain severe personal injury or
death.
10. Properly vent the exhaust of the Model
3600 Infrared Gas Monitor to a safe
area. Improper venting of the
exhaust can cause personal injury or
death.
11. Ensure that the gas sample to the
Model 3600 Infrared Gas Monitor is
clean and dry as possible. Install
filters into the sample inlet fittings as
necessary to obtain a clean and dry
gas sample.
12. Ensure that the gas sample and Model
3600 Infrared Gas Monitor are at the
same temperature; otherwise,
condensation will form and possibly
clog or fill the sample line.
Model 3600 Infrared Gas Monitor Warnings and Cautions

Model 3600 Infrared Gas Monitor

Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-1. Identification Label Location . . . . . . . . . . . . . . . . . . . . . . 1-1
General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Operating Specifications for all Models. . . . . . . . . . . . . . . . . . . . 1-2
Section 2
Installation and Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unpacking the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unpacking the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mounting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Flow Sample Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Sample System Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Sample System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-1. Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Sample System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-2. Bottom View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Opening the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-3. Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Analog Signal Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Relay Connections Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-4. Meter Printed Circuit Board Shown in Configuration 1 2-5
Flow Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Model 3600 Infrared Gas Monitor Table of Contents
TOC - 1

Section 3
Start-up and Initial Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Figure 3-1. Readout and Controls . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Power-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Alarm Setting Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Alarm Level Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Alarm Level Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General Calibration (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Section 4
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Calibration Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Calibration Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Accessing the CalibrationControls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Applying Calibration Gases to the Instrument . . . . . . . . . . . . . . . . . 4-1
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Section 5
Service and Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Troubleshooting Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Service and Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Table 5-1. Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Table 5-2. Replacement Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-3. Calibration Accessories Parts List. . . . . . . . . . . . . . . . . . . . . . 5-2
Table of Contents Model 3600 Infrared Gas Monitor
TOC - 2

Section 1
General Information
The Model 3600 Infrared Gas Monitor
provides a continuous indication of carbon
dioxide or methane concentration. It is
capable of monitoring carbon dioxide from
0.2% to 50% or methane up to 10%
depending on the model. Each instrument is
factory-calibrated to a certain full-scale value
of these two gases.
All Model 3600 Infrared Gas Monitors use
an infrared photo-acoustic sensor. This
sensor gives an indication of the carbon
dioxide or methane levels without requiring
that oxygen be present. Also, this sensor is
not poisoned or degraded in the presence of
silicon or sulfur compounds.
Each Model 3600 Infrared Gas Monitor draws
a gas sample to its internal sensor through a
sample line. The sample line is routed to the
area where gas monitoring is desired. The
Model 3600 Infrared Gas Monitor contains all
the flow components necessary, excluding the
sample line, to properly sample an area.
This manual describes all of the various
Model 3600 Infrared Gas Monitors; your
monitor may not be equipped with all of the
options available. To help you determine
what options are on your unit, there is an
identification label on the side of the
instrument (see FIGURE 1-1). This label
contains the Model number, the gas that
the unit will respond to, and its range. It
also contains information concerning the
proper power voltages and frequency along
with the output signal.
Terminology
The following is an outline of terminology
used in this manual:
ZERO
A zero (0) indication on the meter display
usually indicates ambient air present or no
hazardous gases present.
ZEROING
The process of placing a zero indication on
the meter display.
SPAN
A full-scale or up-scale reading on the
meter display.
SPANNING
The process of placing a full-scale or
up-scale meter reading on the display.
SPAN GAS VALUE
The gas "concentration" that will give the
instrument a full-scale or up-scale value.
This value is printed on the gas cylinder
containing the gas.
FLOW RATE
The speed of the gas in the sample line.
EXHAUST GAS
The gas after it has passed the sensor.
PUMP
An electric motor which drives a device
that moves the gas sample to the Model
3600 Infrared Gas Monitor.
Figure 1-1. Identification Label Location
Model 3600 Infrared Gas Monitor Section 1, General Information
1-1

LO ALARM RELAY
A relay that activates when the gas level
exceeds a low level threshold.
HI ALARM RELAY
A relay that activates when the gas level
exceeds a high level threshold.
General Description
The Model 3600 Infrared Gas Monitor:
•Provides a continuous indication of a
gas or vapor concentration.
•Is capable of measuring Carbon Dioxide
from Parts Per Million (PPM) to 50%.
•Employs photo-acoustic infrared
analysis, and can detect combustible
gases or vapors in applications where
contaminants, interferants, or lack of
oxygen preclude the use of other
techniques.
•(Standard model) is housed in a rugged
plastic enclosure.
•Has a front-panel window that allows
the user to view the meter, the power
LED, and the LEDs indicating each
level of alarm.
•Comes standard with two sets of relay
contacts, a choice of three analog
outputs, and can be powered from one
of six available power supplies.
•Is highly selective to enable operation in
areas with varying humidity or in areas
containing other contaminants. It may be
used for applications requiring long-term
stability and low maintenance.
An optional internally-mounted flow switch is
available to help ensure the sample gas is
getting to the unit. This is especially useful
for sampling dirty or wet remote areas which
may clog the sampling line to the instrument.
Applications
The Model 3600 Infrared Gas Monitor is
factory-calibrated for carbon dioxide or
methane. When calibrated for either of
these gases, the Model 3600 Infrared Gas
Monitor can be used in a wide variety of
industrial applications such as:
•Ventilation control.
•Leak detection of combustible gases
into ambient areas.
•Ambient air monitoring for health and
safety purposes.
•Monitoring levels of combustible gases in
wastewater or sewage treatment plants.
•Flue gas and heat treat systems analysis
•Process monitoring in fermentation,
carbonation, and other food industry
processes.
General Operating Specifications for all Models
PERFORMANCE SPECIFICATIONS
STABILITY SHORT-TERM +1%
LONG-TERM INCLUDING LINEARITY ERROR +5% in 18 months
NOISE +.5% Full-Scale Max.
WARM-UP TIME Five minutes
RESPONSE TIME 97% of a step-change in 12 seconds
OPERATING TEMPERATURES 0 to 50 degrees Centigrade (32 to 122 degrees Fahrenheit)
TEMPERATURE EFFECT <4%/10 degrees Kelvin
RELATIVE HUMIDITY 20 to 99%, RH non-condensing
SAMPLE FLOW RATE 0.8 liters per minute, typical
MAXIMUM TUBING LENGTH 300 feet (100 meters)
OPERATING SPECIFICATIONS
POWER REQUIREMENT 10 VA
ALARM RELAYS One relay for each level of alarm, Form C contacts: 120 VAC, 1 amp resistive
Section 1, General Information Model 3600 Infrared Gas Monitor
1-2

General Operating Specifications for all Models
OPERATING SPECIFICATIONS
ANALOG OUTPUT 4 to 20 mA, or 0 to 1 Volt, or 0 to 10 Volts
MAXIMUM OUTPUT SIGNAL LOAD 500 Ohms
SAMPLE TUBING CONNECTIONS 1/4 inches (6 millimeter) OD; 5/32 inches (4 millimeter) ID
OPTIONAL FLOW SWITCH Dry contact 120 VAC, 1 Amp resistive
DIMENSIONS 7.6 inches high, 7.25 inches wide, 5.3 inches deep.193 millimeters high, 184
millimeters wide, 135 millimeters deep
WEIGHT 4.4 pounds (2 Kilogram)
TRANSPORT AND STORAGE CONDITIONS
TEMPERATURE -40 to +70 Degrees Centigrade
HUMIDITY 99% relative humidity
VIBRATION 7 Gs
INFLUENCE ERRORS
TEMPERATURE <0.4% full scale / Degree Kelvin
HUMIDITY +0.05% full scale / % relative humidity
PRESSURE +0.1% full scale mBar
INTERFERENCE ERRORS
N2, O2, AIR, He No photo-acoustic effect
CH4+4.2 ppm CO2reading/ 1% CH4
CO, SO2, NO, O30.50 ppm CO2reading/ 1%
Model 3600 Infrared Gas Monitor Section 1, General Information
1-3

Section 2
Installation and Set-up
Unpacking the Unit
This section provides instructions on
unpacking and inspecting the equipment,
mounting the monitor, and making electrical
connections to the unit.
Unpacking the System
Carefully remove the Model 3600 Infrared
Gas Monitor from its shipping container(s). To
keep from inadvertently discarding usable or
valuable parts, search through the packing
material and the inside all of the containers.
Remove the closure pin (see FIGURE 1-1) by
sliding it out of the Model 3600 Infrared Gas
Monitor, and open the front cover. Remove all
packing material from inside the unit.
WARNING
Do not operate the unit with the packing
material inside the unit; otherwise, the
unit will not operate properly.
Retain all packaging and packing material
in case it is necessary to return the unit.
Initial Inspection
1. With the front cover open, carefully
inspect the components and
assemblies inside the enclosure.
2. If damage or shortage is noted, advise
the carrier promptly. Make the proper
claim with the carrier.
3. Loosen the two Phillips screws on the
bottom electrical cover to release the
plastic bag (FIGURE 2-3). This bag
contains some mounting hardware
and a sample line filter.
4. Re-install the cover, and tighten the
Phillips screws.
5. Close the front cover, and re-install
the closure pin.
Mounting the Unit
Guidelines
Five rules for proper mounting are:
1. Do not mount the unit to structures
subject to vibration and shock.
2. Do not locate the unit near an excessive
heat source.
3. For proper cooling, allow at least three
inches of clearance around all surfaces,
except for the mounting surface.
4. Do not mount the unit where it will be
exposed to direct sunlight.
5. Mount the unit where the front panel
will not be obscured from view.
Mounting
The monitor should be mounted in a location
that is as free from shock and vibration as
possible. The system should be protected
from extreme vibration. Do not mount in
direct sunlight as this may cause overheating
of the unit. Mount the unit so that its front
panel is not blocked or obscured from view.
Allow four inches of space around the unit
to allow the front door of the instrument
to open fully.
WARNING
These units must not be located in an
area that may contain a flammable
mixture of gas and air; otherwise, an
explosion may occur.
Model 3600 Infrared Gas Monitor Section 2, Installation and Set-Up
2-1

CAUTION
Make sure that the door of the model
3600 Infrared Gas Monitor unit is not
blocked or obscured so as not to block
or obscure the display.
1. Remove the enclosure pin, and open unit.
2. Remove the electrical wiring cover by
loosening the two Phillips screws.
3. Securely mount the Model 3600
Infrared Gas Monitor to a wall or any
flat mounting surface via the four holes
in the back of the instrument, using
the standoffs and screws supplied in
the plastic bag (see FIGURE 2-1).
Ensure that the sample inlet and outlet
on the bottom of the instrument are
pointed downward.
4. Re-install the electrical cover, and
tighten the Phillips screws.
5. Close the front cover, and re-install
the closure pin.
Flow Sample Installation
Sample System Connections
Sample and exhaust fittings are provided
on the Model 3600 Infrared Gas Monitor.
These are barbed fittings designed for use
with 1/4" OD tubing. Route the sample
tubing to the area to be monitored. For
proper operation, the following sample
system requirements must be met.
Sample System Requirements
The following conditions must exist for proper
Model 3600 Infrared Gas Monitor operation:
1. A flowing sample must be maintained
through the unit between 0.5 to 1.0
LPM; if so equipped, the internally
mounted sampling pump is used for
this purpose.
2. Place the end of the sampling line in an
area that will provide the Monitor with
a representative sample; ventilation
Smoke Tubes (P/N 458480) are useful
in determining air flow patterns in
ambient sampling areas.
3. If the sample stream contains toxic or
combustible gases, make sure the
unit is properly exhausted.
4. Ensure the sampling area is free of
particulate matter and condensing
liquids.
NOTE: On an instrument not
equipped with an internal
pump, the sample must be
Figure 2-1. Mounting Dimensions
Section 2, Installation and Set-Up Model 3600 Infrared Gas Monitor
2-2